Heater for an automotive vehicle and method of forming same

ABSTRACT

There is disclosed a heater for an automotive vehicle or other article of manufacture. The heater typically includes a first conductive medium and a second conductive medium disposed upon a carrier. In a preferred embodiment, the first conductive medium includes a first section and a second section that are electrically connected by a second conductive medium. The second conductive medium preferably exhibits a positive thermal coefficient.

CLAIM OF PRIORITY

[0001] To the extent applicable, the present invention claims thebenefit of the priority of U.S. Provisional Application Serial No.60/428,002, filed Nov. 21, 2002 and U.S. Provisional Application SerialNo. 60/474,835, filed May 30, 2003, both of which are incorporatedherein by reference for all purposes.

FIELD OF THE INVENTION

[0002] The present invention relates generally to heaters and moreparticularly to heaters for use in seats, mirrors, handles or otherlocations of automotive vehicles, transportation vehicles or otherarticles of manufacture.

BACKGROUND OF THE INVENTION

[0003] For many years, industry has been concerned with designingimproved heaters for articles of manufacture such as seats, mirrors orhandles of furniture, automotive vehicles or other transportationvehicles. Examples of such heaters are disclosed in U.S. Pat. Nos.6,084,217, 5,451,747, 5,045,673, 4,931,627 and 4,857,711 all of whichare expressly incorporated herein by reference for all purposes.However, the heaters disclosed in these patents suffer from drawbacks.For example, and without limitation, U.S. Pat. No. 6,084,217 employs a“polymeric thick film” and drawbacks with the implementation of suchtechnology have shown that heaters employing such films have beenrelatively inflexible, resulting in the potential for noise resultingfrom body shifting upon a seating surface. Also, these heaters havetraditionally offered only one heat output level when in use. In theinterest of improving upon existing technology in this field, thepresent invention provides a heater that is particularly suitable foruse in seats of automotive vehicles, but which may be adapted forapplication in other transportation vehicles or other articles ofmanufacture as well.

SUMMARY OF THE INVENTION

[0004] According to one aspect of the invention, there is disclosed aheater and a method of forming the same. For forming the heater, aflexible carrier is provided. The carrier is preferably formed of amaterial selected from the group consisting of polymeric materials andfabric materials. The carrier also preferably includes a firstlengthwise edge opposite a second lengthwise edge wherein both the firstand second lengthwise edge having an indentation with at least onecontour. A first conductive medium is typically disposed upon thecarrier. The first conductive medium is preferably formed of a polymericmaterial and preferably includes the following: i) a negative sectionhaving a first base portion and a plurality of first extensionsextending from the first base portion, the first base portion extendingalong the first lengthwise edge of the carrier along the at least onecontour of the first lengthwise edge; and ii) a positive section havinga second base portion and a plurality of second extensions extendingfrom the second base portion, the second base portion extending alongthe second lengthwise edge of the carrier along the at least one contourof the second lengthwise edge. A second conductive medium is alsopreferably disposed upon the carrier. The second conductive mediumtypically includes a plurality of strips wherein each of the strips isin overlapping relation with at least one of the plurality of firstextensions and at least one of the plurality of second extensions.Typically, the second conductive medium has positive thermal coefficientcharacteristics.

[0005] According to another aspect of the present invention, the firstconductive medium includes at least a first section, a second sectionand a third section, wherein the sections are spaced apart. Optionally,each section may comprise one or more extensions or combinations. Asecond conductive medium is also disposed upon the carrier and isinterposed between the spaced sections (e.g. between the extensions ofthe sections). As with the previous aspect of the invention, the secondconductive medium typically has positive thermal coefficientcharacteristics.

[0006] According to yet another preferred aspect of the invention theheater of the present invention is integrated into an article ofmanufacture. As an example, the heater may be integrated into a seat ofan automotive vehicle. The seat typically includes a foam cushion for asupport component of the vehicle seat and the foam cushion preferablyincludes a cavity formed therein. A trim layer will typicallysubstantially cover the foam cushion. The heater preferably disposedbetween the foam cushion and the trim layer. In a preferred embodiment,at least a portion of the heater extends into the cavity of the foamcushion thereby curving the at least one contour of the first baseportion of the first conductive medium and the at least one contour ofthe second base portion or the first conductive medium.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The features and inventive aspects of the present invention willbecome more apparent upon reading the following detailed description,claims and drawings, of which the following is a brief description:

[0008]FIG. 1 is a top view of an exemplary partially formed heater inaccordance with an exemplary aspect of the present invention;

[0009]FIG. 2 is a top view of the exemplary heater in FIG. 1 afterfurther formation of the heater in accordance with an exemplary aspectof the present invention;

[0010]FIG. 2A is a top view of an exemplary alternative electricalconnection suitable for a heater of the present invention.

[0011]FIG. 3 is a blown up side cross-sectional view of the exemplaryheater of FIGS. 1 and 2 with additional exemplary components inaccordance with an exemplary aspect of the present invention;

[0012]FIG. 4 is a partially cut away perspective view of a seat of anautomotive vehicle formed in accordance with an exemplary aspect of thepresent invention;

[0013]FIG. 5 is a top view of a portion of a seat of an automotivevehicle formed in accordance with an exemplary aspect of the presentinvention;

[0014]FIG. 6 is a top view of an exemplary heater for an automotivemirror in accordance with an exemplary aspect of the present invention;and

[0015]FIG. 7 is a cross-sectional view of a mirror assembly inaccordance with an exemplary aspect of the present invention.

[0016]FIG. 8 is a top view of a portion of another heater in accordancewith an exemplary aspect of the invention.

[0017]FIG. 9 is a top view of a portion of yet another heater inaccordance with an exemplary aspect of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The present invention is predicated upon providing an improvedheater suitable for integration into a variety of articles ofmanufacture. For example, the heater may be integrated into or attachedto carriers (e.g., members, structures, panels, floors, walls or thelike) of various articles of manufacture such as buildings, furniture,transportation vehicles (e.g., boats, trains, airplanes, busses) or thelike. Alternatively, the heater may be integrated into or attached tovarious components of transportation vehicles such as seats, mirrors ormirror assemblies (e.g. rearview mirrors, side view mirrors or thelike), gear shifters, panels, footwells, floor mats, cargo or bedliners, windows or other components. The heater is particularly suitablefor integration into a seat of an automotive vehicle. More particularly,the heater is suitable of integration with the seat portion, backportion, head rest portion, or a combination thereof.

[0019] In another automotive application, the present invention may beused in a steering assembly. As such, the heater may be placed on orintegrated with various regions of a steering wheel including the hub,wheel, spokes, turn signal or shifter of the steering wheel assembly.Likewise, the heater of the present invention may be located anywherethroughout the vehicle, and most advantageously, with components thatgenerally come in contact with an occupant of the vehicle including armrest, rear view mirrors, user control interfaces and otherwise.

[0020] Outside of the automotive application, it is foreseeable that thepresent invention may be incorporated into other applications includingBed mattresses, wheel chairs, articles of clothing, or any other objectthat may come into contact with a person.

[0021] Furthermore, the present invention may be used outside ofpersonal comfort applications including: infrared sensing technology,heating electrical or mechanical components or even heating a fluidthrough a submersion of the heater or an application to the outer wallsof a container. Also, the heater may include or be integrated with: anantenna for reception or transmission of radio frequencies; a sensorsuch as a seat occupant sensor (e.g. for use with an airbag orotherwise), or a sensor for children car seats; a warning device forsignaling an alarm when a temperature (internal or otherwise) of thevehicle is undesirably high or low; combinations thereof or the like. Insome or all of the previous applications, the heater may be configuredwith a pressure sensor to determine the presence of an applied forceacting on the heater or the sensor.

[0022] The heater of the present invention may exhibit one or moreadvantages as compared to previous heaters. As one example, the heatermay control its heat output without employing components such as acontroller, a thermostat, a temperature sensor, combinations thereof orthe like. Of course, it is contemplated that these components may beincluded with the heater to assist in controlling or regulating theamount of heat output by the heater. As another advantage, the geometry,sizing, materials and configuration of the heater and its components canassist in forming a more effective heating system within a vehicle seator other article of manufacture. As an example, a preferred heater maybe formed of materials that add flexibility to the heater for assistingin minimizing noise that might otherwise be produced by the heater. Asanother example, a preferred heater may include one or more contours,openings or cavities for aiding the bending of the heater therebyallowing the heater to conform to contours of an article of manufactureparticularly for assisting in attaching the heater to the article.

[0023] In one or more alternate embodiments, the heater of the presentinvention may also be adapted to selectively activate one or moreregions of the heater to provide selective heating, to manipulate theheat output generated by the heater or both. In the one or morealternate embodiments, a user can preferably control one or both of thelocation and intensity of heat provided by the heater of the presentinvention.

[0024] Generally, the heater of the present invention will include oneor a combination of the following components:

[0025] 1) a carrier that is preferably configured as a flexible panel;

[0026] 2) a first conductive medium disposed upon the carrier, the firstconductive medium preferably including a first section and a secondsection wherein each section preferably includes a base portion and aplurality of extensions extending from the base portion;

[0027] 3) a second conductive medium for interconnecting the firstsection to the second section, the second conductive medium preferablyincluding a plurality of resistive strips, which preferably interconnectthe plurality of extensions of the first section to the plurality ofextensions of the second section wherein the second conductive mediumpreferably exhibits positive thermal coefficient characteristics.

[0028] Optionally, the first conductive medium can include a thirdsection for assisting the heater in providing multiple heat outputlevels or for allowing selective heating of different locations of theheater.

[0029] Referring to FIGS. 1, 2 and 3, there is illustrated the formationof an exemplary heater 10 in accordance with the present invention. Theheater 10 includes a first conductive medium 12 and a second conductivemedium 14 disposed upon a carrier 18. Generally, the heater 10 isconfigured as a flexible panel (i.e., with opposing surfaces and athickness therebetween) although other shapes or configurations may beemployed as well.

[0030] For example, while in one embodiment the carrier 18 may beflexible, it is foreseeable that the carrier may alternatively be rigidor semi-rigid or non existent altogether (discussed in greater detailbelow). Regardless of the rigidity characteristics of the carrier 18,the carrier may be formed in numerous shapes and configuration asdesired depending on the application (e.g. seat, seat back, head rest,mirror, steering wheel, or any other article that may be heated toenhance the environment for a user). Moreover, the carrier may includecontours for assisting in stress relief particularly when the heater maybe subject to stresses from pressure, movement or otherwise.

[0031] The carrier 18, as illustrated, is configured as panel withopposing surfaces 26, 28. As seen in the particular embodiment of FIGS.1, 2 and 5, the carrier 18 is substantially elongated and generallyrectangular and more preferably is hourglass shaped. As shown, thecarrier 18 has a length (L) and a width (W) and includes an outerperipheral edge 22 extending substantially continuously about thecarrier 18 substantially defining the shape of the carrier 18. Theperipheral edge 22 is shown to include a first lengthwise edge 32opposing a second lengthwise edge 34.

[0032] In the particular embodiment illustrated, the first lengthwiseedge 32 and the second lengthwise edge 34 have cutouts for helping toform the hourglass shape. For example, the lengthwise edges 32, 34respectively define a first indentation 38 and a second indentation 40,which respectively define a first concavity 44 and a second concavity46. The first indentation 38 generally opposes and is substantially amirror image of the second indentation 40. Both indentations 38, 40 mayinclude one or a plurality of contours 48, 50, 52 at least partiallydefining the cavities 44, 46. In the particular embodiment illustrated,both indentations 38, 40 include two pair of opposing convex contours48, one pair of opposing concave contours 50 and one central concavecontour 52. The carrier 18 may also include an opening 58 locatedbetween the first and second indentations 38, 40 and which is generallyrectangular.

[0033] The heater, carrier or both may be shaped as desired and suchshape may depend upon the application of the heater. Thus, the carrieror heater shape should not limit the present invention unless otherwisestated. As examples, the heater, carrier or both may includeconfigurations that are circular, oval, elliptical, square, rectangular,geometric, non-geometric, symmetric, or asymmetric, or combinationsthereof or the like. Furthermore, the heater, the carrier or both may bepreformed (e.g. as planar or contoured) to correspond to an article suchas a steering wheel or other article. Alternatively, the heater, thecarrier or both may be flexible to allow of such correspondence.

[0034] In a preferred embodiment of the present invention, the carriermay be attached to one or more components of an article of manufacture(e.g. a seat, a mirror or the like). Alternatively, a first carrier mayprovide a release surface, which allows the first and second conductivemedium to be transferred to one or more components of the article suchthat the one or more components become the carrier. This may be achievedaccording to various techniques such as appliques, dissolvablesubstrates, removable substrates, or the like. Alternatively, the firstand second conductive medium may be placed on one or more of thecomponents of the article itself through printing, spraying, rolling,dabbing, brushing, pouring, or the like, again such that the one or morecomponents become the carrier of the heater.

[0035] It is contemplated that the carrier 18 may be conductive,nonconductive, or partially conductive. This includes electricconductivity, thermal conductivity and diffusion. Also, for attachmentpurposes, the carrier may be configured to hold and maintain a staticcharge thereby allowing the carrier to attach itself to a component ofan article (e.g. a mirror assembly, a seat or the like), with or withoutthe use of adhesion or fastening techniques.

[0036] Alternatively, or in combination with the above, the carrier mayfurther include one or more adhesive materials or layers for attachingthe carrier to a component. The adhesive material may be applied to thecarrier or, the carrier itself may comprise of adhesive material or haveadhesive characteristics. The adhesive may be applied using suchtechniques as printing, spraying, rolling, dabbing, brushing, pouring orotherwise placed on one or both sides of the carrier.

[0037] The carrier 18 may be formed from various materials includingpolymeric materials such as plastics, elastomers, thermoplastics,composites or the like. The carrier 18 may also be formed of woven ornon-woven fabric materials, paper materials, impregnated fibers, fibrousmaterials or the like. The carrier 18 preferably has a thickness betweenabout 1 micron or less and 1 centimeter or greater, more preferablybetween about 10 microns and 1 millimeter, still more preferably betweenabout 50 microns and about 200 microns.

[0038] One preferred material for the carrier is a polyester film thatis commercially available under the tradename MELINEX®, designationnumber ST505, from the DuPont Company. Another preferred material forthe carrier is a spunbound Olefin that is commercially available underthe tradename TYVEK® also from the DuPont Company. Still anotherpreferred material for the carrier is a polyester film that iscommercially available under the tradename CETUS®, designation numberCP2101, from the Cetus Company. Yet another preferred material for thecarrier is a nylon polyester or polyether imide that is commerciallyavailable under the tradename ULTEM®, designation number 1000 orotherwise, from the General Electric Corporation.

[0039] Of course, other types of base substrate material are availablefor the carrier such as ceramic, glass, polymeric material (e.g.plastic, elastomers, thermoplastic, thermoset, or the like), polyesters,polyethylene, Mylar, woven material (e.g. nylon or cloth), or otherwise.

[0040] Preferred carriers have advantageous properties such as strength,flexibility, rigidity, elasticity, dielectric properties, a combinationthereof or the like depending upon their application. Carriers may alsobe transparent, opaque, reflective or the like. Preferably, carriers aretemperature resistant (e.g. up to 80° C. or more). Furthermore, carriersmay exhibit relatively high acceptance to screen printing materials(e.g. polymers).

[0041] In preferred embodiments, particularly for seating applications,but for other applications as well, materials used for the carrier ofthe present invention exhibit an elongation at failure of as much orgreater than 15%, more preferably greater that 35%, even more preferablygreater than 50% and still more preferably greater than 70%. Also inpreferred embodiments, the material used for the carrier of the presentinvention exhibit a dielectric constant of up to or greater than 0.5,more preferably greater than 1.0 and even more preferably greater than2.0.

[0042] The first conductive medium 12 may be disposed upon the carrier18 in a variety of configurations (e.g., in spaced parallel lines,zig-zags, serpentine, opposing interdigitated lines, etc.). Typically,the first conductive medium 12 is divided into a first or negativesection 70 and a second or positive section 72 that are spaced apartfrom each other upon the carrier 18. Preferably, the negative section 70does not directly electrically connect with the positive section 72. Asused herein the terms “positive” and “negative” are only used becauseone of the sections 70, 72 will be electrically connected to a positiveterminal of a power source while the other is electrically connected toa negative terminal as is further described below. It shall beunderstood that the sections 70, 72 may be interchanged or switched.Preferably, each of the sections 70, 72 respectively includes a baseportion 74, 76 and a plurality of extensions 80, 82 extending outwardlyfrom the base portions 74, 76. As shown, the plurality of extensions 80of one section 70 are spaced apart from the plurality of extensions 82of the other section 72. Moreover, the plurality of extensions 80 of thenegative section 70 are spaced apart from each other and the pluralityof extensions 82 of the positive section 72 are also spaced apart fromeach other.

[0043] In the particular embodiment illustrated, the base portion 74 ofthe negative section 70 extends along substantially the entire firstlengthwise edge 32 of the carrier 18 while the base portion 76 of thepositive section 72 extends along substantially the entire secondlengthwise edge 34 of the carrier 34. As such both base portions 74, 76include the same indentations 38, 40, cavities 44, 46 and contours 48,50, 52 as the lengthwise edges 32, 34 of the carrier 18. The baseportions 74, 76 also include an opening 88 extending down the center ofthe base portions 74, 76 adjacent the indentations 38, 40, cavities 44,46 and contours 48, 50, 52.

[0044] The extensions 80, 82 are illustrated as elongated fingers thatextend from one of the base portions 74, 76 toward the other of the baseportions 74, 76 without actually contacting the other of the baseportions 74, 76. As shown, particularly in FIG. 1, wherein only thefirst conductive medium 12 is disposed upon the carrier, the extensions80 of the negative section 70 are interdigitated or intermittent withrespect to the extensions 82 of the positive section 72 thereby forminggaps 90 between the extensions 80, 82.

[0045] The first conductive medium 12 may be formed of a variety ofmaterials such as metals, conductive plastics, combinations thereof orthe like. While it is contemplated that the first and second sections70, 72 of the first conductive medium 12 may be formed of differentmaterials, it is preferred that they be formed of one material. In apreferred embodiment, the first conductive medium 12 is formed of apolymeric material, which may be printed (e.g., screen printed) upon thecarrier 18.

[0046] As an exemplary embodiment, the material for the first conductivemedium 12 is a polymeric material such as a polymer thick filmcomposition sold under the tradename POLYMER SILVER CONDUCTOR 5025,commercially available from DuPont, 1007 Market Street, Wilmington, Del.19898. In such an embodiment, the first conductive medium 12 istypically screen printed upon the carrier 18 such that the medium 12 hasa thickness of about 2 micrometers to about 4 millimeters, morepreferably about 6 micrometers to about 1 millimeter and even morepreferably about 12 to about 15 micrometers. Once printed, theconductive medium 12 is typically exposed to heat for curing. Forexample the carrier 18 and medium 12 may be placed within a box oven andthe medium 12 cured for about 1 to about 10 minutes at a temperaturebetween about 80° C. and about 180° C., more preferably for about 3 toabout 8 minutes at a temperature between about 100° C. and about 140°C., still more preferably about 5 to about 6 minutes at a temperature ofabout 115° C. to about 125° C. As an alternative example, for areel-to-reel screen printer, the carrier 18 and medium 12 may be exposedto temperatures of about 100° C. to about 200° C. for about 20 secondsto about 3 minutes, more preferably temperatures of about 120° C. toabout 160° for about 40 seconds to about 2 minutes, still morepreferably a temperature of about 140° C. for about one minute forcuring the medium 12.

[0047] While, one or more configurations for the base portions have beendiscussed, it is contemplated that the base portions of the presentinvention may be arranged in numerous alternative configurations aswell. As such, the base portions may be on opposite, adjacent or samesides of a carrier or may partially or completely overlapping having aninterposed insulating material. The shape of the base portions may begeometric or non-geometric. Similarly, the base portion may besymmetrical or asymmetrical in shape. Some possible base portion shapesinclude: shapes having one or more arcuate boarders (e.g. round,circular, elliptical, oval, helical, combinations thereof or the like),shapes having one or more linear boarders (e.g. rectangular, square,equilateral or the like). It is also contemplated that the base portionsmay include a variety of both arcuate and linear borders.

[0048] In other embodiments, one base portion may be partially or fullyenclosed within the other base portion. As an example, a first U-shapedbase portion could partially surround a second corresponding U-shapedbase portion with interdigitated or otherwise configured extensionsextending from the base portions. As another example, a first baseportion may be shaped in an enclosed configuration (e.g. as a circle,square, rectangle or the like) such that the second base (which may beof corresponding or non-corresponding shape) portion is substantiallyenclosed within the first base portion. In either example, the heatermay include extensions in any configuration described herein.

[0049] While only two base portions are shown, it is foreseeable thatadditional base portions may be used. Also, the number of electricallypositive base portions may or may not be equal to that of theelectrically negative base portions.

[0050] Accordingly, as with the base portions, the extensions can bearranged in different patterns with respect to the base portions andeach other. Some possible patterns include interdigitated serpentine,straight, curved, spiral, rectangular, zigzag, or otherwise. In theembodiment shown in FIG. 2, each first extension from the first baseportion is separated from the next closest first extension by no morethan one second extension from the second base portions However, it iscontemplated that a first extension from the first base portion may beseparated from the next closest first extension by two or more secondextension from the second base portion. In such an embodiment, it ispreferably although not required that the second conductive mediuminterconnects only first extensions from the first base portion withsecond extensions from the second base portion.

[0051] Additionally, it is contemplated that two sections of the firstconductive medium may form an overlapping relationship in order tocreate a more desirable circuit for selective heat generation of theheater. For example, as illustrated in the embodiment shown in FIG. 9,though discussed in greater detail below, a first section of the firstconductive medium may be configured in an overlapping relationship witha second section. In such an instance, an insulating or nonconductingmaterial typically interposes the first and second sections, to preventcurrents from traveling directly from one section to another sectionwithout passing through the second conductive medium. Of course, directpassage of current between sections may be desirable in some instances(e.g. such that current only passes through a portion of the secondconductive medium). However, the first and second sections mayalternatively be interposed by the second conductive medium, orotherwise to provide a heating circuit. For example, a second conductivemedium may be sandwiched between a portion of the first and secondsection. As such, when a current travels from the first and secondsection, it is possible for the second conductive to generate heattherebetween.

[0052] This overlapping relationship of the different sections of thefirst conductive medium provides the ability to form more intricatecircuit designs. One advantage of having more intricate circuits is theability to generate multiple heat outputs from a single heating unit.Another advantage is the ability to provide a heating unit having morethen one heating regions that are selectively activated.

[0053] In any of the possible base portion configurations, the width andthickness of the portion may be consistent throughout, variable, orprogressively narrowing or expanding. Likewise, the width and thicknessof an extension from the first or second base portions may beconsistent, variable, or progressively narrowing or expanding.Furthermore, the thickness, length and width of the first and secondextensions may vary throughout the heater. Moreover, the extensions maybe parallel, skew, nonparallel or the like relative to each other, thebase portions, the extensions from the other base portion or relative tothe second conductive medium.

[0054] As with the base portions, the extensions from either of the baseportions may overlap each other wherein nonconductive medium is placedbetween the overlapped regions.

[0055] The material of the base portion and the extensions may be thesame or different material depending on the application. Moreover, theextensions may be interconnected by the second conductive medium suchthat the base portions are connected.

[0056] Alternatively, it is contemplated that there are no extensionsand the base portions are in direct contact with a conductive medium.Examples of this configuration includes the overlapping of the baseportions having an interposed conductive medium. In another example, thebase portions may be configured adjacently, or otherwise, having aconductive material interposed. In the above examples, the applicationof more than two base portions may be desired.

[0057] Referring to FIGS. 2 and 3, the second conductive medium 14 maybe disposed upon the carrier 18 in a variety of configurations. Thesecond conductive medium 14 may be continuous, intermittent, planar,geometric, contoured, combinations thereof or the like. Preferably, thesecond conductive medium 14 electrically connects the positive section72 of the first conductive medium 12 with the negative section 70 of thefirst conductive medium 12.

[0058] In the exemplary embodiment illustrated in FIG. 2, the secondconductive medium 14 includes a plurality of strips 94, which are shownas separate from each other, but which may be interconnected. Each ofthe strips 94 is elongated and extends with and/or preferably parallelto the extensions 80, 82 of the first conductive medium 12 and eachstrip 94 electrically connects an extension 80 of the negative section70 with an extension 82 of the positive section 72. As shown, each ofthe strips 94 overlaps and directly contacts one extension 80 of thenegative section 70 and one extension 82 of the positive section 72.

[0059] It is also for preferred, but not necessarily required, that eachof the plurality of strips 94 have substantially the same size and shapeand that the strips 94 be substantially uniformly spaced apart from eachother. Moreover, it is preferable for the strips 94 to have uniformdensities compared to each other and throughout each strip 94. In thismanner, the heater 10 can typically produce a more uniform heatintensity along the length and/or width of the heater 10.

[0060] The second conductive medium 14 may be formed of a variety ofmaterials including metal, plastics or combinations thereof. Preferably,the material exhibits relatively high positive thermal coefficient (PTC)as will be discussed further below. While it is contemplated that thestrips 94 may be formed of different materials, it is preferred thatthey be formed of one material. In a preferred embodiment, the secondconductive medium 14 is formed of a polymeric material, which may beprinted (e.g., screen printed) upon the carrier 18.

[0061] In an exemplary embodiment, the material for the secondconductive medium 14 may be a polymeric material such as a polymer thickfilm composition sold under the tradename PTC CARBON RESISTOR 7282,commercially available from DuPont, 1007 Market Street, Wilmington, Del.19898. In such an embodiment, the second conductive medium 14 istypically screen printed upon the carrier 18 such that the medium 14 hasa thickness of about 1 micrometer to about 1 millimeter, more preferablyabout 3 micrometers to about 10 micrometers and even more preferablyabout 6 to about 8 micrometers. Alternate printing methods include silkscreen printing, ink jet printing or the like. Once printed, theconductive medium 14 is typically exposed to heat for curing. Forexample, the carrier 18 and medium 14 may be placed within a box ovenand cured for about 2 to about 30 minutes at a temperature between about90° C. and about 200° C., more preferably about 5 to about 15 minutes ata temperature of about 110° C. to about 150° C., still more preferablyabout 10 minutes at temperature of about 130° C. As another example, fora belt drier, the carrier and medium 14 may be exposed to temperaturesof about 110° C. to about 210° C. for about 1 minute to about 20minutes, more preferably temperatures of about 130° C. to about 170° forabout 2 minutes to about 10 minutes, still more preferably a temperatureof about 150° C. for about 3 to about 5 minutes.

[0062] Other conductive mediums used in the above printing methodsinclude aqueous polymers including conductive fillers (e.g. conductivemetal powder, metallic oxide, silver, copper or otherwise), resistivefillers (e.g. carbon or otherwise), films (e.g. polyurethane, UV curablePolymeric dielectric composition, thermosetting resins (e.g. epoxies,phenol resins, or the like), or otherwise), ethylene vinyl acetateco-polymer resin having black carbon or a combination thereof.Preferably, the ink is impermeable to light and may include one or moreof the following binders: resin-based acrylic ink, borosilicatelead-glass, thermosetting resins (e.g. epoxy, phenol, melamine resin),or conductive powder.

[0063] The second conductive medium may be applied in a variety ofpatterns alternative to that which is shown. In one embodiment, theconductive medium may emulate (e.g. extend parallel) the pattern of thefirst and second base portion. Preferably, the conductive medium is atleast partially interposed between the extensions of the first andsecond base portions. When provided as strips or otherwise, theconductive material may be parallel, angled, skew, perpendicular,serpentine with respect to the extensions of the base portions or thebase portions themselves. Also the pattern of the second conductivemedium may be comprised of concentric or non-concentric geometricconfigurations, e.g. circles, squares, oval, or otherwise. Furthermore,the second conductive medium may be randomly or systematically placebetween extension of the base portions, or between the base portions,and may comprise a plurality of strips having cut out portions. Thestrips of the conductive material may also be sectioned or broken intopieces.

[0064] While preferred material for the first and second conductivemediums have been disclosed, it is contemplated that other materials maybe employed as layers or otherwise for providing part or all of thefirst and second conductive mediums. Examples of these materialsinclude: foil tape, transfer paper, strips sheets, sleeves, strands ofelectrically conductive thread, wire, deposited metal, plated material,sewn material or otherwise. Other materials include: metals (e.g.aluminum, chromium, nichrome, or otherwise), carbon, film, foam (eitherthermally or non thermally conductive) (e.g. Comfortem® by foaminternational), electrically conductive woven fabric having a conductivecoating such as silver, polymeric material (applied as a film orprinted, discussed more below).

[0065] The heater 10 of the present invention also typically includesone or more (e.g. a pair of) electrical connections 100, 102.Preferably, each of the connections 100, 102 is respectively in electriccommunication with one of the base portions 74, 76 of the negative andpositive sections 70, 72.

[0066] It shall be understood by those skilled in the art that a varietyof electrical connections may be employed. In the particular embodimentof FIG. 2, each of the electrical connections 100, 102 includes a wire104 (e.g., a coated copper conductive wire) having an end 106 that isattached (e.g. soldered) to a foil patch 108 (e.g., of electricallyconductive tape) and the patch 108 with the end 106 is attached (e.g.,adhered) to one of the base portions 74, 76. In an alternative exemplaryembodiment, and referring to FIG. 2A, an electrical connection 110 isemployed wherein a member 112 includes a rivet 114 connected to one ofthe base portions 74 and an eyelet 116 connected to a wire 120.

[0067] Advantageously, the heater of the present invention may be formedwith only one or two electrical connections for providing a currentthrough the base portions, the extension, the second conductive medium(e.g. the strips) or a combination thereof. Of course, additionalconnections may be used if desired or needed. As an added value, theheater 10 can be formed with the entirety of the first and secondconductors supported by the single carrier 18 without requiringadditional layers for supporting the conductors. Of course, additionallayers may be used if needed or desired.

[0068] The electrical connections may be located on the same side of thecarrier. Alternatively, the electrical connections may be located onopposite or adjacent sides of the carrier. Also, the electricalconnections may be diagonally opposite each other on the carrier. Thus,the electrical connections may be situated such that the summation ofthe electrical paths between adjacent portions of the extension aresubstantially equivalent or substantially non equivalent.

[0069] The electrical connections may be integrated into a single unit,having both positive and negative leads, or may be separated into two ormore connections. Furthermore, the electrical connections may beintegrated into a single extension or “tail”, or multiple “tails”, usedto electrically connect the heater to a power or energy source (e.g. abattery).

[0070] The heater of the present invention may be capable of operatingat one or multiple heat outputs. Various techniques may be used forproducing multiple heat outputs. For example, referring to FIGS. 8 and9, two or more circuits may be configured to operate at different outputlevels and may be disposed or printed on one, two or more carriers.Alternatively, referring to any of the embodiments contained herein, twoor more sets of electrical connections could deliver different energylevels (e.g. voltages) to one, two or more circuits printed onto one,two or more carriers. Moreover, one, two or more electrical connectionsmay be configured for delivering different output levels for deliveringdifferent output levels to the above configured heaters.

[0071] The present invention may further comprise one or more controlsafety features including: thermostat, control module with NegativeTemperature Coefficient (NTC) resistor, Positive Temperature Coefficientfuse or some other temperature sensing device. Also, a ConstantTemperature Coefficient (CTC) may be used for eliminating the effect ofthe temperature of the heating element on the amount of heat generatedby the heating element. The above features can allow the system to shutdown upon sensing of excessive temperatures or a short in the system.

[0072] Also, the present invention may be configured with one or moreswitches (e.g. a latch switch or momentary switch), for applying acurrent to the heater of the present invention. For example, a controlmodule may be used in conjunction with a momentary switch for turningthe heating device on and off. Alternatively, a switch (e.g. an on/offswitch) may be used to physically connect and/or disconnect a circuitthat includes the heater with an energy source. Other switches that maybe used includes a voltage control potentiometer, multiple positionswitch for allowing choice of temperature settings (e.g. high-low-off),multi-pole switch or otherwise.

[0073] The heater of the present invention is electrically connected toan energy source to generate a current through the heater to produceheat. The energy source may provide an alternating current, a directcurrent, or a combination thereof. In an automotive application,preferably the heater is electrically connected to an automotive energysupply, (e.g. 12 volt battery). Alternatively, or additionally, theheater may be connected to the alternator, control module or otherelectrical components in the vehicle.

[0074] In any of the discussed embodiments, including FIG. 3, aninsulation layer 130 may be laminated over the conductive mediums 12, 14of the heater 10. The insulation layer 130 may be formed of fleece,gauze or the like and may be fastened to the carrier 18 via adhesive orotherwise.

[0075] While FIG. 3 has been illustrated with an insulation layer 130,it is contemplated that the heater 10 may advantageously be formedwithout any such additional insulation layer 130. Moreover, it iscontemplated that the insulation layer 130 may be provided by the seat(e.g., as part of a trim layer) and that the insulation material may notbe specifically adhered or otherwise attached to the heater 10. Theapplication of the insulating material is numerous and at a minimumincludes the methods used below in applying the protective coating.

[0076] As another option, the first conductive medium 12, the secondconductive medium 14 or both may be fully or partially covered with aprotective coating. In a preferred embodiment, the first and secondconductive mediums 12, 14 are coated with a protective dielectriccoating formed of a polymeric dielectric composition. Preferably, thecoating is curable (e.g., UV curable), solvent less or a combinationthereof. The coating may be applied to the conductive mediums 12, 14 byseveral methods such as printing, spraying, rolling, dabbing, brushing,pouring or the like, but is preferably screen printed upon the mediums12, 14. The coating may be up to 5 millimeters thick or greater and ispreferably between about 10 microns and about 4 millimeters thick, morepreferably between about 100 microns and about 3 millimeters thick(e.g., between about 1 to about 1.2 millimeters thick). In a preferredembodiment, the protective layer has electrical, or thermal, insulatingcharacteristics.

[0077] Materials available for both the insulating layer and protectivelayer include the same materials used for the carrier. Additional layersthat may be used for the insulating and protective layers havingdi-electric properties include: paper, film (e.g. polyurethane, UVcurable polymeric dielectric composition, thermosetting resins orotherwise), vinyl sheet, fleece, gauze, flexible sheets (e.g.elastomeric, polyester terephthalate, polycarbonates, or otherwise),foam (e.g. thermally conductive, non-thermally conductive, polyurethane,neoprene, or otherwise), glass or the like. However, a protective layermay be conductive in certain layered configurations.

[0078] In any of the embodiment of the present invention, it iscontemplated that an adhesive is disposed on either side of the carrieror conductive mediums prior to the heater of the present invention beingapplied to a specific article (e.g. a seat cover, mirror or otherwise).It is also contemplated that adhesives may be on both sides of thecarrier to adhere to one or more additional components associated withthe heater such as a protective layer or otherwise. Also, it iscontemplated that no adhesives are used in the present invention butinstead static electricity or some other self attachment is used tomount or fix the heater to a specified region of the article.

Vehicle Seat and Mirror Applications

[0079] As previously discussed, the heater 10 of the present inventionmay be integrated into various articles of manufacture. Referringspecifically to FIGS. 4 and 5, as an example, the heater 10 is shownintegrated into a seat 140 of a vehicle. The heater 10 of the presentinvention may be located in various portions of an automotive vehicleseat such as a support portion, a backrest portion, a shoulder supportportion or a headrest. The heater may be located between the trim of theseat and the foam cushioning of the seat. The heater may also beintegrated into the trim of the seat, the foam cushioning of the seat orboth.

[0080] Referring to FIG. 4, the seat 140 is illustrated with the heater10 of FIGS. 2 and 3 positioned in both a seat backrest component 142 anda seat support component 144. In the embodiment illustrated, eachcomponent 142, 144 of the seat 140 includes a trim layer 146 and a foamcushion 148 and each of the heaters 10 is positioned substantiallybetween the foam cushion 148 and trim layer 146. Preferably, each heater10 is fastened to the seat 140 (e.g., the trim layer 146, the cushion148 or both) for maintaining the heater 10 stationary relative to theseat 140. It is also contemplated that tape 150 (e.g., two-way tape), asshown in FIG. 3, or other fasteners or adhesives may be employed tofasten the heater 10 to the seat 140 and particularly the foam cushion148.

[0081] In a highly preferred embodiment shown in FIG. 5, a centralportion 160 of the heater 10 is tied down atop a foam cushion 162 of aseat with the central portion 160 extending at least partially into acavity 164 (e.g., a trench) of the cushion 162. As shown, tie strings170 extend through the opening 58 over the top of the central portion160 of the heater 10 to tie the heater 10 down. Advantageously, thecontours 48, 50, 52 of the carrier 18 and the first conductive medium 12curve about foam cushion 162 at the cavity 164 when the central portion160 of the heater 10 is extended into the cushion 162 thereby relievingstress that might otherwise be placed upon the first conductive medium12 and particularly the base portions 74, 76 of the first conductivemedium 12. Moreover, the opening 58 also serves to relieve stress as thecentral portion 160 of the heater 10 is extended into the cushion. Whilethe contours 48, 50, 52 and opening 58 have been employed for relievingstress during application to a foam cushion 162, it should be understoodthat the contours 48, 50, 52 and opening 58 may also assist in relievingstress wherever the heater 10 curves about an object to which it isapplied.

[0082] In one alternate embodiment, the present invention is integratedwith a mirror assembly. In such an embodiment, the shape of the heater,carrier or both is likely to change to the corresponding shape of themirror assembly. An example of such an embodiment is shown in FIG. 6,wherein the heater 10 is configured with a carrier 18, a firstconductive medium 12 and a second conductive medium 14.

[0083] The first conductive medium 12 is preferably configured with afirst base portion 74 and a second base portion 76 having associatedfirst and second oppositely charged electrical connectors 100, 102respectively. Preferably, the shape of the first and second baseportions 74, 76, the carrier 18 or both conform to the shape of themirror 12, backing or both. Furthermore, it is contemplated that thefirst and second base portions 74, 76 may have varying widths as theyextend along the carrier 14.

[0084] Extending from the first and second base portions 74, 76 are aplurality of interdigitted first and second extensions 80, 82 havingvarying lengths (e.g., becoming progressively larger or smaller)according to the contours of the first and second base portions 74, 76and the contours of the mirror. Preferably the extensions 80, 82 areparallel with respect to each other, however, other configurations arecontemplated as disclosed herein. Also, other patterns are contemplatedas disclosed herein.

[0085] Preferably, each of the sections 70, 72 respectively includes abase portion 74, 76 and a plurality of extensions 80, 82 extendingoutwardly from the base portions 74, 76. As shown, the plurality ofextensions 80 of one section 70 are spaced apart from the plurality ofextensions 82 of the other section 72. Moreover, the plurality ofextensions 80 of the negative section 70 are spaced apart from eachother and the plurality of extensions 82 of the positive section 72 arealso spaced apart from each other.

[0086] Alternatively in another embodiment, referring to FIG. 7, theheater 10 of the present invention may be applied to, or incorporatedwith, a mirror assembly 180 (e.g. side mirror, rear view mirror, or thelike). The mirror assembly 180 is typically configured with a mirror182, a mirror backing 184 and a housing 186, although each component isnot necessarily required. In the illustrated embodiment, the heater 10includes a carrier 18 that is attached to the mirror 182, the backing184 or both. Alternatively, however, it is contemplated that the mirror182 or backing 184 may be the carrier for the conductive mediums of theheater 10.

[0087] The carrier 18 may be applied to (e.g. attached to) the mirror182, the backing 184 or both using a variety of techniques. In oneembodiment, the attachment of the heater 10 to the mirror 182 or backing184 may be accomplished with adhesives, fasteners, combinations thereofor the like. Alternatively, the heater 10 may be attached without theuse of adhesives or fasteners. For example, the heater 10 may bestatically adhered to the mirror 182 or backing 184. As anotheralternative, the carrier 18 may be composed of a material havingadhesive characteristics for adhering the heater 10 to the mirrorassembly 180.

[0088] Alternatively or additionally, it is contemplated that the mirrorassembly may be configured for securing the heater 10 to itself. Forexample, the mirror 182, the backing 184 or both may include one or morerecesses for receiving and securing the heater 10 thereto. As anotherexample, the heater 10 may be sandwiched and secured between the mirror182 and the backing 184. Moreover, the mirror assembly 180 may beconfigured with integral fasteners (e.g. snap-fits) for securing theheater 10.

[0089] In addition to the first conductive medium 12 and the secondconductive medium 14, the electrical connectors 100, 102 may be directlyattached to the mirror 182, the backing 184 or both. Advantageously, anyportion of the heater 10 not disposed or incorporated on a portion ofthe mirror assembly 180, may be adhered or fastened to the mirrorassembly 180 using any of the techniques described herein. For example,the mirror 182 or backing 184 may be coated with the second conductivemedium 14 while the first conductive 12 medium may be placed over thesecond conductive 14 according to a different technique. Further, it iscontemplated that the mirror 182 contacts either the first conductivemedium, the second conductive medium or both. Optionally however, one ormore additional layers (e.g. insulating, protective, otherwise or acombination thereof) as described herein may be place over the firstconductive medium 12 as desired.

[0090] In operation, the heater 10 can operate to heat the mirror 182 insubstantially the same manner as the heater can be used to heat a seat.Advantageously, the heater can assist in removing water in the form ofcondensation, frost or otherwise from the mirror 182.

Operation

[0091] In operation, and referring to FIGS. 2 and 4 one electricalconnection 102 is connected to a positive terminal of an electricalpower source (not shown) and the other connection 100 is connected to anegative terminal of the electrical power source. In turn, when thepower source provides electrical energy to the heater 10, an electricalcurrent flows from one electrical connection 100 to the base portion 74of the negative section 70 of the first conductive medium 12. Theelectricity then flows to the extensions 80 of the negative section 70and through the strips 94 of the second conductive medium 14 to theextensions 82 of the positive section 72 of the first conductive medium12. Thereafter, the electricity flows to and through the base portion 76of the positive section 72 of the first conductive medium 12 and out ofthe heater 10 through the electrical connection 102. Due to theresistance of the second conductive medium 14, the strips 94 elevate intemperature thereby heating the seat 10, and particularly the trim 146of the seat 140. Advantageously, the strips 94 of the second conductivemedium 14 exhibit positive thermal coefficient characterization suchthat the strips 94 are self-limiting with regard to how warm they willbecome. More specifically, for a particular voltage applied to thesecond conductive medium 14, the resistance of the second conductivemedium 14 will rise, which in turn, causes the current flowing throughthe second conductive medium 14 to become lower until an equilibrium isattained. As will be recognized by the skilled artisan, variousvariables such as the voltage applied to the heater, the composition ofthe second conductive medium 14, the size and configuration of thesecond conductive medium 14 and others may be varied such that theequilibrium for the medium 14 is achieved at desired heat output. It isalso contemplated that, after use, the resistance of the secondconductive medium may shift (e.g., upwardly shift) between about 15% andabout 25%. If such is the case, it is typically desirable to design theconfiguration of the second conductive medium to account for the shiftwhile still producing the preferred heat output.

[0092] In preferred embodiments, the distance between the positivesection of the first conductive medium and the negative section of thefirst conductive medium (i.e., the distance that the second conductivemedium spans to interconnect the sections) may be set to assist incontrolling the temperature of the second conductive medium, the heateror both during operation. In the preferred illustrated embodiment, theextensions 82 of the positive section 72 are typically separated fromthe extensions 80 of the negative section 70 by a distance of about 0.5millimeter to about 1 centimeter, more preferably about 1.5 millimetersto about 5 millimeters, still more preferably about 3 millimeters. Alsoin the preferred embodiment, the second conductive medium 14, the heater10 or both reach a temperature between about 0.0° C. and about 100° C.,more preferably between about 25° C. and about 80° C., still morepreferably between about 50° C. and about 70° C.

[0093] In addition to the previous embodiments, it is also contemplatedwithin the scope of the present invention that the heater can include afirst conductive medium having at least three sections, which areinterposed by a second conductive medium. In such an embodiment allthree sections of the first conductive medium can be electricallyconnected through the second conductive medium thereby providing theability to form multiple heating circuits. For example, one or morecircuits may be created between a first and second section, the firstand third sections, the second and third section or between all threesections. Also, with the use of a first conductive medium having atleast three sections, numerous circuits may be selectively generatedbetween any two sections having an interposed second conductive medium.As such, preferred heating regions may be generated.

[0094] In this alternate configuration, one section of the firstconductive medium is connected to a first or positive terminal andanother section is connected to a second or negative terminal of a powersupply for forming a first heating circuit. By connecting yet anothersection of the first conductive medium to the positive or negativeterminal of a power supply, a second heating circuit may be generatedbetween this section and any other section (e.g., the aforementionedsections or additional sections) connected to an oppositely chargedterminal.

[0095] Advantageously, a switching device, as disclosed herein, may beused for selectively and electrically connecting the sections of thefirst conductive medium to the positive or negative terminal of a powersupply. Moreover, it should be understood that the materials discussedfor the carrier, the first and second conductive mediums may also beappropriately employed in the following embodiments and may be appliedas previously discussed. It is also contemplated that the followingembodiments may include an insulation layer that may be formed of thesame materials and applied to the carrier, the conductive medium or acombination thereof as described in the previous embodiments.

[0096] Accordingly, as shown in FIGS. 8 and 9, (FIG. 9 reference numbersin brackets) there are illustrated two examples of an exemplary heater190 (290) that is configured with a first conductive medium 192 (292)having at least three sections applied to a carrier 194 (294). The atleast three sections include a first section 202 (302), a second section204 (304) and a third section 206 (306). Preferably, the first, secondand third sections 202, 204 and 206 (302, 304 and 306) are eachrespectively configured with a base portions 208, 210 and 212 (308, 310and 312) and a plurality of extensions 214, 216 and 218 (314, 316 and318) respectively extending from the base portion 208, 210 and 212 (308,310 and 312). As with the other embodiments contained herein, it iscontemplated that each of the first, second and third sections 202, 204and 206 (302, 304 and 306) are further configured with electricalconnections 220 (330) adapted for connecting the at least three sectionsto a power source. Advantageously, a control device (e.g., a switchingdevice or other device) is used for selectively connecting the at leastthree sections to a positive or negative terminal of a power supply.

[0097] Generally it is contemplated that sections of the firstconductive medium 192 (292) may be connected through the secondconductive medium 226 (326). For example, it is contemplated that anyextension, base portion, or other part of a section may be connected toany other extension, base portion or other part of a section through anapplication of the second conductive medium 226 (326) over a portion orall of the carrier 194 (294). In this exemplary embodiment, the firstconductive medium 192 (292) is applied to the carrier 194 (294) and isoptionally partially or fully covered by a second conductive medium 226(326). As such, a completed circuit may be achieved by electricallyconnecting i) the power supply, ii) any section of a first conductivemedium, iii) the second conductive medium, and iv) any other section ofa first conductive medium, wherein each completed circuit may heatdifferent portions of the heater and/or change its heat output.Advantageously, a switching device may be utilized to selectively directcurrent through the first and second conductive medium.

[0098] A user can energize any two sections of the at least threesections to heat a region of the second conductive medium locatedbetween the two sections. Likewise, a user can energize more than twosections, of the at least three sections to heat additional regions ofthe second conductive medium to increase the overall heat output of theheater 190 (290).

[0099] Referring to FIG. 8 in more detail, a portion of the heater 190is configured with a first conductive medium 192 applied to a carrier194. The first conductive medium 192 is configured with at least threesections, namely the first, second and third sections 202, 204 and 206.

[0100] The first section 202 is preferably centrally located withrespect to the width of the carrier 194 and comprises a base portion 208that extends along the length of the carrier 194. Extending transverseto the length of the carrier 194 is a plurality of spaced apartextensions 214, which are preferably skew (e.g. substantiallyperpendicular) to the first base portion 208. Advantageously, theextensions may extend out from one or both sides of the first baseportion 208 and optionally, extensions extending from one side may bealigned or staggered relative to extensions extending from the oppositeside. Though not shown, the first section 202 is connected to aswitching device, which selectively connects the first section 202 toeither a negative or positive terminal of a power supply.

[0101] The second section 204 comprises two base portions 210 whichextend along the length of the carrier 194 and preferably coextensive(e.g., substantially parallel) with the the first base portion 208. Aswith the first base portion 208, the second base portions 210 areconfigured with a plurality of spaced apart second extensions 216 thatextend transversely relative to the length of the carrier 194 and arepreferably skew (e.g., substantially perpendicular) to the second baseportions 210. As with the first extensions 214, the second extensions216 extend from both sides of the second base portions 210. However, incontrast to the first extensions 214, the second extension 216 areextending from one side of the base portions 210 the are shown asstaggered with respect to extensions 216 extending from the other sideof the base portions 210 but may alternatively be in an alignedconfiguration.

[0102] Advantageously, the spaced apart second extensions 216 interposethe first extensions 214 and are in an interdigitated configuration. Thefirst and second extension are spaced apart from each other andinterposed by strips of second conductive medium 226, or otherwise,which preferably overlaps at least a portion of the first and secondextensions 214, 216. In the embodiment shown, the second conductivemedium 226 that is located between the first and second extensions 214,216 forms a first heat region 228. Both of the second base portions 210are connected to a switching device, which can selectively connect thesecond section 204 to the terminal, opposite in charge, to the firstsection 202.

[0103] The third section 206 comprises a single third base portion 212which extends about the periphery of at least a portion of the carrier194 and more preferably about the majority of the periphery. However, itshould be appreciated that it is not necessary for the third baseportion to extend about the majority of the periphery as the third baseportion 212 may be segmented into two or more third base portions 212.As with the first and second base portions 206, 208, the third baseportion 212 is configured with a plurality of spaced apart thirdextensions 218 that extend transversely relative to the length of thecarrier 194 and preferably extend skew (e.g. substantiallyperpendicular) to the third base portion 212. In this exemplaryembodiment, the third extensions 218 extend from one side of the thirdbase portions. In this configuration, the extensions of the thirdsection extend inward toward the second base portions so as to becomeinterposed and interdigitated with second extensions 216 that extendtoward the third base portion.

[0104] The second and third extensions 216, 218 are spaced apart fromeach other and interposed by strips of second conductive medium 226, orotherwise, which preferably overlaps at least a portion of the secondand third extensions 216, 218. The second conductive medium 226 locatedbetween the second and third extensions 216, 218 form a second heatingregion 230. The third base portion 212 is connected to a switchingdevice, which selectively connects the third section 206 to theterminal, opposite in charge, to either the first section 202 or thesecond section 204. Preferably the third base portion 212 is selectivelyconnected to the terminal which is opposite in charge to the secondsection 204.

[0105] Referring to FIG. 9 in more detail, a portion of a heater 290 isconfigured with a first conductive medium 292 applied to a carrier 294.As with the exemplary embodiment illustrated in FIG. 8, the firstconductive medium 292 is configured with at least three sections, namelythe first, second and third sections 302, 304 and 306. However, in thisconfiguration at least one overlapping relationship exits between the atleast three sections.

[0106] The first section 302 is preferably centrally located withrespect to the second and third section 304, 306 and comprises a baseportion 308 that extends along the length of the carrier 294. Extendingtransverse relative to the length of the carrier 294 is a plurality ofspaced apart extensions 314 (though only one is shown), which arepreferably skew (e.g., perpendicular) to the first base portion 308. Theextensions 314 are shown as extending from one side of the first baseportion 308, but may extend out from one or both sides of the first baseportion 308. Preferably, The first section 302 is connected to aswitching device through an electrical connection 320, which selectivelyconnects the first section 302 to either a negative or positive terminalof a power supply.

[0107] The second section 304 comprises a second base portion 310extending along the lengthwise edge of the carrier 294. The second baseportion 310 is shown as being substantially coextensive with (e.g.,parallel to) and adjacent the first base portion 308, although notnecessarily required. The second section 302 is typically connected to aswitching device through an electrical connection 322, which selectivelyconnects the second section 302 to the negative or positive terminal ofthe power source. Preferably, the second section 302 is selectivelyconnected to a terminal different than the first section 302 (e.g., thefirst section is selectively connected to a positive terminal when thesecond section is connected to a negative terminal and vice versa). Aswith the first base portion 308, the second base portions 310 isconfigured with a plurality of spaced apart second extensions 316 thatextend transverse relative to the length of the carrier 294 and theextensions 316 are preferably skew (e.g., substantially perpendicular)to the second base portion 310. Due to the centrally locatedconfiguration of the first section 302 (e.g., between the second andthird sections), the second extensions 316 are shown in an overlappingrelationship with the first base portion 308.

[0108] In one configuration, the first base portion 308 and the secondextensions 316 may be directly in contact with each other. However, in apreferred arrangement, the first base portion 308 and the secondextensions 316 are spaced apart by a spacer 332. One example of a spacer332 comprises a substantially electrically non-conductive orelectrically insulating material located between the first base portion308 and the second extensions 316. Though non-conductive materialsavailable for such an application are numerous, a few examples mayinclude glass, plastic, rubber, elastomeric or polymeric materials orotherwise and may be applied using any technique contained herein orotherwise. It is also contemplated that the material describedpreviously for the insulative layer may also be employed.

[0109] In another example, the spacer 332 may comprise a layer of secondconductive medium 326. In such a configuration, the spacer may generateheat with the application of a current traveling through the spacer(e.g., second conductive medium 326) from the first base portion 308 tothe second extensions 316 or vise versa.

[0110] Advantageously, the spaced apart second extensions 316 interposethe first extensions 314 and are in an interdigitated configuration. Thefirst and second extension are spaced apart from each other andinterposed by strips of second conductive medium 326, or otherwise,which preferably overlaps at least a portion of the first and secondextensions 314, 316. The second conductive medium 326 located betweenthe first and second extensions 314, 316 form a first heat region 328.Both of the second base portions 310 are connected to a switchingdevice, which selectively connects the second section 304 to theterminal, which is opposite in charge to the first section 302.

[0111] The third section 306 comprises a base portion 312 extendingalong a lengthwise edge, opposite to the second base portion 310, of thecarrier 294 and is coextensive with (e.g., parallel to) the first baseportion 308. Preferably, The third section 304 is connected to aswitching device through an electrical connection 324, which selectivelyconnects the third section 304 to either the negative or positiveterminal of a power supply. Preferably, the third section 306 isconnected to an oppositely charged terminal than that of the secondsection 304, although not required.

[0112] As with the first and second base portion 306, 308, the thirdbase portion 312 is configured with a plurality of spaced apart secondextensions 318 that extend transverse relative to length to the carrier294 and preferably extend skew (e.g. perpendicular) to the third baseportion 312. In the configuration depicted, the extensions extendtowards the first and second base portions 308, 310 and are interposedby the first and second extensions 314, 316.

[0113] Advantageously, the spaced apart third extensions 318 interposethe first and second extensions 314, 316 and are in an interdigitatedconfiguration. The second and third extensions 316, 318 are spaced apartfrom each other and interposed by strips of a second conductive medium326, which preferably overlaps at least a portion of the second andthird extensions 316, 318. The second conductive medium 326 locatedbetween the second and third extensions 316, 318 form a second heatregion 330. The third base portion 312 is connected to a switchingdevice, which selectively connects the third section 306 to theterminal, opposite in charge, to either the first section 302 or thesecond section 304. However, preferably the third base portion 312 isselectively connected to the terminal which is opposite in charge to thesecond section 304, although not required.

[0114] It should be appreciated that the patterns shown in FIGS. 8 and 9may repeat throughout a portion of the carrier or the entire carrier. Itshould also be appreciated that the exemplary embodiment shown in FIGS.8 and 9 may be configured with any of the advantages as disclosedherein. For example, any of the materials, patterns, methods, additionalfeatures or otherwise, as previously discussed in other embodiment orotherwise contained herein, may be included with the exemplaryembodiments contained in FIGS. 8 and 9. Likewise, any of the featuresdisclosed in FIGS. 8 and 9 may be wholly, or in part, included with anyother embodiment or example contained herein to form the presentinvention.

Operation of the Heaters of FIGS. 8 and 9

[0115] Turning to a discussion of operation, referring to exemplaryembodiment shown in FIG. 8, the heater 190 is illustrated havingcircuitry configured to enable the selection of one or more regions tobe heated, to control the amount of heat output from the heater 190, ora combination thereof. As previously discussed, the heater 190 isconfigured with a first conductive medium 192 having at least threesections 202, 204 and 206, which are interposed by a second conductivemedium 226 and selectively connected to a positive or negative terminalof a power supply. As such, any two sections of the first conductivemedium 192 that are connected to oppositely charged terminals of a powersupply form a circuit and thereby generates heat in the region locatedtherebetween.

[0116] In a first mode of operation, a switching device (not shown)electrically connects the first section 202 of the first conductivemedium 192 to a positive or negative terminal of a power source andconnects the second section 204 to the other terminal. The connectioncreates a circuit for flowing electric current between the first andsecond sections 202, 204 through the second conductive medium 226. Asdiscussed earlier, the application of a current through the secondconductive medium 226 results in the generation of heat in the secondconductive medium 226 located between the first and second sections 202,204 thereby creating the first heated region 228. Also as discussedearlier, the amount of heat output is typically dependent upon thecircuit's configuration such as dimensions (e.g. width, thickness or thelike) of the conductive materials, properties (e.g., conductivity, PTCcharacteristics or the like) of the second conductive medium, currentbeing applied to the second conductive medium or otherwise.

[0117] In the particular embodiment illustrated, the first heated region228, is generally defined by the second conductive medium locatedbetween the first and second extensions 214, 216. As such, the firstheated region may be considered, in the first mode of the exemplaryembodiment of FIG. 8, as the area located between the upper most firstextension 214 and the lower most second extension 216. However, itshould be appreciated that the definition of the heated region isdependent on the flow of current through the second conductive medium226. As such, alternate applications of second conductive medium, or thechange in the direction or amount of current or otherwise, may changethe location or size of the first heat region 228. For example, with thefirst extensions 214 extending from both sides of the first base portion208, with interposing second extension 216, the first heated region 228may comprise the second conductive medium 226 interposed between thefirst and second extensions 214, 216 on either side of the first baseportion 208 or both sides. Alternatively, the first heated region 228may be divided into two separate heat regions as so desired. As such, inthis example, it is contemplated that one or both of the second baseportions 210 are electrically connected to an opposite terminal of apower supply to that of the first base portion 208.

[0118] In a second mode of operation, the switching device selectivelyconnects the first section 202 of the first conductive medium 192 to thepositive or negative terminal of a power source and the third section206 to the other terminal. This connection creates a circuit between thefirst and the third sections 202, 206 through the second conductivemedium 226 thereby resulting in the heating of the second conductivemedium 226 located there between. As such, a second heated region 234 isgenerated in this mode of operation.

[0119] In a more descriptive discussion of the second mode, as electriccurrent leaves the first extensions 214, it travels through the secondconductive medium 226, through the non-connected second section 204and/or extensions thereof, through the second conductive medium 226again, and into the third extension 218. Of course, alternate currentpaths are also contemplated within the scope of the present invention.For example, the second conductive medium 226 may electrically bridgethe second section (e.g., through use of insulation materials). In suchan embodiment, the area between the first and third extensions 214, 218could generally defines the second heat region 234. Also, as in thefirst mode of operation, with the first extensions 214 extending fromboth sides of the first base portion 208, with adjacently located thirdextensions 218, the second heated region 234 may comprise the secondconductive medium 226 interposed between the first and third extensions214, 218 on either side of the first base portion 208 or both sides.Alternatively, second heated region 234 may be divided into two separateheat regions as so desired. As such it is contemplated that one or bothof the third base portions 212 are selectively and electricallyconnected to an opposite terminal of a power supply to that of the firstbase portion 208.

[0120] In this second mode of operation, it is foreseeable that not onlydoes the heat region change in location and size, but also the amount ofheat being generated may vary due to the difference in area or amount ofsecond conductive medium 226 subject to the applied current.

[0121] In a third mode of operation, the switching device selectivelyconnects the second section 204 to the positive or negative terminal ofa power source and the third section 206 to the other terminal. Thiscreates a circuit between the second and third extensions 216, 218through the second conductive medium 226 thereby resulting in theheating of the second conductive medium located there between. As such,the third heated region 230 is generated.

[0122] Similar to that of the first heat region 228, the second heatedregion is generally defined by the second conductive medium locatedbetween the second and third extensions 216, 218 and may include anyextension located there between. As such, the heated region may beconsidered, in the third mode, as the area located between the uppermost second extensions 216 and the lower most third extensions 218.However, as previously discussed, it should be appreciated that thedefinition of the heated region is dependent upon the flow of currentthrough the second conductive medium 226. Again, similar to that of thefirst mode of operation, with the second extensions 216 extending fromboth of the second base portion 210, with interposed third extensions218, the third heated region 230 may comprise the second conductivemedium 226 interposed between the second and third extensions 214, 218adjacent to either of the second base portion 210 or both base portions210. Alternatively, second heated region 234 may be divided into twoseparate heat regions as so desired. As such it is contemplated that oneor both of the second or third base portions 210, 212 are selectivelyand electrically connected to an opposite terminal of a power supply tothat of the other second or third base portions 210, 212.

[0123] In the third mode of operation, the heat output will likely besimilar to or the same as with the heat output of the first mode due tothe similarity in spatial relationship and the amount of secondconductive medium 226 located between the extensions 216, 218. However,differently configured sections and/or materials could produce variabledifferent heat outputs.

[0124] In a fourth mode of operation, the switching device selectivelyconnects the first and third sections 202 and 206 to the positive ornegative terminal of a power source and the second section 204 to theother terminal. This creates a circuit between first and secondextension 214, 216 and the second and third extensions 216, 218 throughthe second conductive medium 226. This mode of operation issubstantially the same or similar to the simultaneous operation of firstand third mode because the first and second heat regions 228, 230 arebeing heated at least partially at the same time. As such, the heatoutput, in the fourth mode, may be the sum of the output found in thefirst and third mode of operation (e.g., approximately double the heatoutput). Of course, such summation of heat outputs assumes the samelevels of current crossing the second conductive medium 226 as in thefirst and third mode of operation. It is also contemplated that variousvoltage levels may be applied to offer different heat output levels.

[0125] With the selective application of the four modes of operation, asdescribed above, it is possible to have at numerous heat output levels.For example, a lowest heat output level may comprise the second heatregion 234 on one side of the first base portion 208 due to the reducedamount of second conductive medium 226 being subjected to an electricalcurrent as compared to other heat regions (e.g., 228, 230). A higherheat output level may comprise the second heat regions 234 located onboth sides of the first base portion 208. Yet a still higher heat outputlevel may comprise the first heat region 228 or third heat region 230 asdescribed above, or combinations thereof. It should be apparent thenumerous heat output levels may be created with the three heat regions.It should also be apparent that this is but one circuit configuration ofthe present invention and with the addition of other configurationscomes the ability to create yet more circuits and heat output levels.

[0126] Now referring to the exemplary embodiment shown in FIG. 9, theheater 190 again is illustrated having circuitry configured to enablethe selection of one or more regions to be heated, the one or moreamounts of heat output from the heater 190, or a combination thereof. Aspreviously discussed, the heater 190 is configured with a firstconductive medium 192 having at least three sections 202, 204 and 206,which are interposed by a second conductive medium 226 and selectivelyconnected to a positive or negative terminal of a power supply. As such,any two sections of the first conductive medium 194 that are connectedto oppositely charged terminals of a power supply can form a circuit andthereby generate heat in the region located there between.

[0127] As discussed, the heater 290 of FIG. 9 includes an overlappingrelationship between its sections and the overlapping portions mayinclude a spacer 332 located therebetween for preventing a current fromshorting or traveling to an undesired location or otherwise. Though, attimes, it may be desirous to electrically connect the overlappingportions of the first and second sections 302, 304 or alternatively,interpose a second conductive medium 326 there between for thegeneration of yet another heating region.

[0128] Typically, the spacer 332 comprises a substantiallynon-conductive material so that opposite currents can travel through theoverlapping portions of first and second sections 302, 304 withoutcausing a short or otherwise interfering with current flow.

[0129] In a first mode of operation, a switching device (not shown)electrically connects the first section 302 of the first conductivemedium 292 to a positive or negative terminal of a power source andconnects the second section 304 to the other terminal. The connectioncreates a circuit between the first and second extensions 302, 304through the second conductive medium 326 and generates the first heatregion 328. The first heated region is generally defined by the secondconductive medium 326 located between the first and second extensions314, 316, but may be otherwise defined.

[0130] In a second mode, the switching device selectively connects thefirst section 302 to the positive or negative terminal of a power sourceand the third section 306 to the other terminal. This connection resultsin the heating of the second conductive medium 326 located between thefirst and second extensions 314, 316 and the second and third extensions316 and 318. Therefore, in this configuration, the heated regions 328and 330 will produce heat as the current will travel from the firstextensions 314 through the second conductive medium 326, through thenon-connected second extensions 316, through the second conductivemedium 326 again, and into the third extension 318.

[0131] Assuming continuity in the illustrated pattern of the heater,this mode of operation can result in heating all strips of conductivematerial. However, with different extension arrangements ordiscontinuities in the application of the second conductive medium 326,the heating of the entire carrier 294 may be less than complete.

[0132] In a third mode, the switching device selectively connects thesecond section 304 to the positive or negative terminal of a powersource and the third section 306 to the other terminal. This connectionresults in the heating of the second conductive medium 326 locatedbetween the second and third sections 304, 306 thereby generating heatedregion 330. Assuming size and spatial similarities between the secondand third extension, as compared to the the first and second extension,the amount of heat generated in this mode can be similar to that of thefirst mode. Of course, changes in size and spatial relationship canprovide different heat outputs.

[0133] In a fourth mode, the switching device selectively connects thefirst and third sections 302 and 306 to the positive or negativeterminal of a power source and the second section 304 to the otherterminal. This configuration results in the second conductive medium 326located between the first and second extension 314, 316 and the secondand third extension 316, 318 being heated, e.g. the first and secondheat regions 328, 330.

[0134] The amount of heat generated in this fourth mode may or may notbe similar to that of the second mode due to the amount of secondconductive medium 326 being subjected to a current, the distance betweenthe extensions, or otherwise or combinations thereof. However, incontrast to the second operation mode, it is contemplated that theamount of current traveling through the circuit may increase due to theadditional extension (e.g. second extension 314) applying a current. Assuch, the amount of heat output may increase or the elapsed timerequired to heat the heater may decrease or both.

[0135] It should be appreciated that circuitry illustrated in both FIG.8 and FIG. 9 may comprise all or a portion of a given heating circuit.Likewise the circuits may be combined with each other or any othercircuits to form the heater of the present invention.

[0136] Also, while the second conductive medium is illustrated betweenall of the extension, it should be appreciated that the secondconductive medium may be selectively applied between the extensionsthereby changing the flow of current through the sections of the heater,the second conductive medium or both.

[0137] Although the heaters illustrated include two or three sections,it is contemplated that the heaters may be configured with more thanthree or less than two sections, which can be selectively connected to apower supply.

[0138] Furthermore, it is contemplated that the current applied to anyof the circuits contained herein may be controllably varied to achieve adesired heat output. For example, a control unit may be utilized toapply a first voltage to the heater in a first mode and apply a secondvoltage in a second mode, which may be higher or lower than the firstvoltage. As such, the application of power to the circuit may vary,which may further vary the heat output of the heater.

[0139] In these later embodiments, as exemplified through FIGS. 8 and 9,it is contemplated that any of the additional features that may be usedwith the heater of the present invention, as discussed with otherembodiment contained herein or otherwise, may also be used in theselater embodiments. As an example, additional layers may be used, whichmay include insulating, adhesive or protective layers. Likewise, theselater embodiments may be used in any of the application as containedherein (e.g., seats, mirrors, steering wheels or otherwise).

[0140] Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

[0141] The preferred embodiment of the present invention has beendisclosed. A person of ordinary skill in the art would realize however,that certain modifications would come within the teachings of thisinvention. Therefore, the following claims should be studied todetermine the true scope and content of the invention.

What is claimed is:
 1. An article of manufacture, comprising: a carrierof the article of manufacture, the carrier having a surface; a heateroverlaying the surface, the heater including; i) a flexible carrier; ii)a first conductive medium disposed upon the carrier wherein the firstconductive medium includes: 1) a negative section having a plurality offirst extensions; and 2) a positive section having a plurality of secondextensions; and iii) a second conductive medium that includes aplurality of strips, each of the strips in overlapping relation with oneof the plurality of first extensions and one of the plurality of secondextensions, the plurality of strips also extending substantiallyparallel to the first and second extensions.
 2. An article as in claim 1wherein the carrier of the heater and the first conductive mediumcooperatively define at least one contour, which bends about a contourof the article.
 3. An article as in claim 2 wherein the carrier of theheater has an hour-glass shape.
 4. An article as in claim 3 wherein thecarrier of the heater has a centralized opening defined adjacent the atleast one contour.
 5. An article as in claim 1 wherein the heaterincludes a first electrical connection and a second electricalconnection.
 6. An article as in claim 5 wherein the only electricalconnections of the heater are the first and second electricalconnections.
 7. An article as in claim 1 wherein the plurality of stripsis substantially uniformly spaced apart from each other.
 8. An articleas in claim 1 wherein each strip of the plurality of strips hassubstantially the same shape.
 9. An article as in claim 1 wherein eachstrip has a substantially continuous density throughout.
 10. An articleas in claim 1 wherein the carrier is formed of a material having adielectric constant greater than
 1. 11. An article as in claim 1 whereinthe carrier is formed of a material having an elongation at failuregreater than 15%.
 12. An article as in claim 1 wherein the carrier isformed of a material having an elongation at failure greater than 50%.13. A seat of an automotive vehicle, comprising: a foam cushion for asupport component of the vehicle seat, the foam cushion having a cavity;a heater overlaying the cushion, the heater including; i) a flexiblecarrier formed of a material selected from the group consisting ofpolymeric materials and fabric materials, the carrier including a firstlengthwise edge opposite a second lengthwise edge, both the first andsecond lengthwise edge having an indentation with at least one contour;ii) a first conductive medium disposed upon the carrier, the firstconductive medium being formed of a polymeric material wherein the firstconductive medium includes 1) a negative section having a first baseportion and a plurality of first extensions extending from the firstbase portion, the first base portion extending along the firstlengthwise edge of the carrier along the at least one contour of thefirst lengthwise edge; and 2) a positive section having a second baseportion and a plurality of second extensions extending from the secondbase portion, the second base portion extending along the secondlengthwise edge of the carrier along the at least one contour of thesecond lengthwise edge; and iii) a second conductive medium thatincludes a plurality of strips, each of the strips in overlappingrelation with only one of the plurality of first extensions and only oneof the plurality of second extensions, the plurality of strips alsoextending substantially parallel to the first and second extensions, thesecond conductive medium having a positive thermal coefficient; and atrim layer substantially covering the foam cushion; wherein the heateris tied down to the foam cushion such that the heater curves at the atleast one contour of the carrier.
 14. An article as in claim 13 whereinthe carrier has a centralized opening between the indentation of thefirst lengthwise edge and the indentation of the second lengthwise edge.15. An article as in claim 13 wherein the heater includes a firstelectrical connection and a second electrical connection and wherein thefirst and second electrical connections are the only electricalconnections of the heater.
 16. An article as in claim 13 wherein theplurality of strips is substantially uniformly spaced apart from eachother and each strip of the plurality of strips has substantially thesame shape.
 17. An article as in claim 13 wherein each strip has asubstantially continuous density throughout.
 18. An article as in claim13 wherein the carrier is formed of a material having a dielectricconstant greater than
 1. 19. An article as in claim 13 wherein thecarrier is formed of a material having an elongation at failure greaterthan 15%.
 20. An article as in claim 13 wherein the carrier is formed ofa material having an elongation at failure greater than 50%.
 21. Aheater, comprising: a carrier; a first electrically conductive mediumhaving at least three sections disposed upon the carrier, wherein the atleast three sections includes: i) a first section; ii) a second sectionspaced apart from the first section; and iii) a third section spacedapart form the first and second section; and a second electricallyconductive medium electrically connecting the first, second and thirdsections, wherein at least two of the at least three sections areselectively electrically connected to a positive or a negative terminalof a power supply.
 22. The heater of claim 21, wherein the selectiveconnection of the at least three sections to the positive or negativesection of the power supply results in the heater selectively having atleast three temperature settings.
 23. The heater of claim 21, whereinthe selective connection of the at least three sections to the positiveor negative section of the power supply results in the heater havingdifferent heated regions.
 24. The heater of claim 21, further comprisinga switch for selectively connecting the at least two of the at leastthree sections to the positive or negative terminal of the power supply.25. The heater of claim 21, wherein the carrier comprises a flexiblematerial.
 26. The heater of claim 22, wherein the second conductivemedium comprises a Positive Thermal Coefficient (PTC) material.
 27. Theheater of claim 21, wherein one of the at least three sections overlapsanother of the at least three sections.
 28. The heater of claim 21,wherein the at least three sections are disposed upon the carrieraccording to a pattern.
 29. The heater of claim 28, wherein the patternis selected from serpentine, straight parallel, cruved parallel,zig-zag, spiral parallel, rectangular parallel or a combination thereof.30. The heater of claim 21, wherein the at least three sections arefurther configured with extensions spaced apart from one another. 31.The heater of claim 30, wherein the at least three sections disposedupon the carrier form a interdigitated pattern.
 32. A heater for anarticle of manufacture, comprising: a flexible carrier; a firstelectrically conductive medium having at least three sections disposedupon the carrier, wherein the at least three sections includes: i) afirst section having one or more first extensions; ii) a second sectionhaving one or more second extensions; and iii) a third section havingone or more third extensions, wherein the extensions of at least one ofthe three sections are adjacent to the extensions of another of thethree sections; and a second electrically conductive medium electricallyconnecting the first, second and third sections, wherein at least two ofthe at least three sections are selectively connected with a positive ora negative terminal of a power supply, and wherein selective connectionresults in at least three heat output levels of the carrier.
 33. Theheater of claim 32, wherein the selective connection of the at leastthree sections results in the heater having different heated regions.34. The heater of claim 32, further comprising a switch for selectivelyconnecting at least two of the the three sections to the positive ornegative terminal of the power supply.
 35. The heater of claim 32,wherein at least one of the heat output levels is zero.
 36. The heaterof claim 32, wherein the first, second and third extensions aresubstantially uniformly spaced apart from each other.
 37. The heater ofclaim 32, wherein the extensions of the at least three sections form apattern selected from interdigitated, zig-zag, serpentine, straightparallel, cruved parallel, spiral parallel, rectangular parallel or acombination thereof.
 38. The heater of claim 32, wherein the heater isconfigured for attachment to an article of manufacture selected from amirror or a seat.
 39. The heater of claim 32, wherein at least oneoverlapping relationship exist between the at least three sections. 40.An article of manufacture, comprising: a carrier of the article ofmanufacture, the carrier having a surface; a heater overlaying thesurface, the heater including; a flexible carrier; a first conductivemedium having at least three sections disposed upon the carrier, whereinthe at least three sections includes: i) a first section; ii) a secondsection spaced apart from the first section; and iii) a third sectionspaced apart form the first and second sections; and a second conductivemedium electrically connecting the first, second and third sections,wherein at least two of the at least three sections are selectively andelectrically connected with a positive or a negative terminal of a powersupply thereby generating heat, and wherein selective connection resultsin at least three heat output levels of the heater.
 41. An article as inclaim 40, wherein the carrier is selected from a seat or mirror.
 42. Anarticle as in claim 40, wherein each of the at least three sections ofthe heater further comprises an electrical connector.
 43. The heater ofclaim 40, wherein the selective connection of the at least two of the atleast three sections to the positive or negative terminal of the powersupply results in the heater having different heated regions.
 43. Theheater of claim 40, further comprising a switch for selectivelyconnecting the at least two of the three sections to the positive ornegative terminal of the power supply.